Foamable silicate composition



EXAMlNER 6 8 6 mass REFERENCE United States Patent 0 3,268,350- Patented August 23, 1966 If the high silica containing residues obtained from 3,268,350 iron product-ion are employed, these ordinarily will con- FOAMABLE SILICATE COMPOSITION John J. Grebe, John F. Miller, Wayne L. Rhiuehart, and Thomas R. Wayt, Midland, Mich., assignors to The Dow Chemical Company, Midland, Mich., a corporation of Delaware No Drawing. Filed June 13, 1962, Ser. Nari-02,111

2 Claims. (Cl. 106-75) tain an excess of SiO Sodium oxide values can be added to establish the operable Na O/SiO ratio. With low silica containing ores excess of silicon dioxide will be added to insure the proper ratio of reactants.

If the composition is prepared from individual components, the Si0 concentration is calculated in accordance with the total predetermined ratio of Na O/SiO This invention relates to foams and more particularly 10 desired in the composition. is concerned with inorganic silicatefoams, a process for The maximum amount of sodium oxide to be used their preparation and products prepared therefrom. is somewhat less than that required for sodium silicate It is a principal object of the present invention to pro- (Na O.SiO formation since a portion of the silicon videalightweight, fireproof foam. dioxide enters into reaction with the metal oxides to It is another object of the present invention to proform the corresponding silicate or metal oxide-silicon vide a foamable composition that can be foamed without dioxide complex oxide. using chemical foaming agents as are conventionally Although the sodium values employed are expressed m l d. herein as sodium oxide, conveniently this alkali metal base It is a further object of the present invention to prois introduced into the foamable composition as sodium hyvide an inorganic silicate glass foam which has a reladroxide or sodium carbonate instead of the oxide itself. tively slow set time, is easy to handle during molding Likewise, metal oxide formers, such as metal hydroxide, and possesses a uniform cell structure. hydrolyzable metal salt or other metal compounds which It is an additional object of the present invention to are decomposed or transformed into the oxides during the provide an inorganic foamed product having excellent original fusion glass slag producing reaction can be emthermal insulating properties which product can be used ployed as the memide source. at high temperatures. As has been shown hereinbefore, the foamable novel These and other objects and advantages will be apcomposition readily can be prepared by fusing the indiparent from the detailed description presented hereinvidual components or by incorporating sodium oxide and/ after, or silicon dioxide values as required into the residues re- The foamable composition of the present invention maining from conventional iron ore reduction practices. comprises a mixture of Na O (sodium oxide) and SiO Advantageously, however, the present novel foamable (silicon dioxide) of Na O/SiO proportions ranging on composition can be produced directly in an iron producing a molar basis from about 1/ 1.2 to about 1/3.5 and process wherein a mixture of an iron ore associated with preferably from about 1/ 1.2'to about 1/ 1.6 plus one or siliceous material, a carbonaceous substance and sodium more metal oxides from Groups IA, IIA, IIIA, IVB, hydroxide, sodium oxide or sodium carbonate is heated to VIB, VIIB, and VIII of the periodic table as presented a temperature sufiicient to render the iron molten. In in Handbook of Chemistry and Physics, 41st ed., this process a fixed carbon/R 0 molar ratio of 0.5 to pp. 448-449, Chemical Rubber Publishing 00., Cleveland, 4.5 is employed and Na O/SiO molar ratio of from 0.25 Ohio (1960). Hereinafter, the term metal oxide reto 4is used. fers to the oxides in this latter group of additives and A sodium silicate glass-like slag having metal oxide siliexcludes sodium oxide. cates in combination therewith is coproduced with the The minimum concentration of metal oxide to be emmetallic iron. The incorporation of additional reactants, ployed in the composition is that amount whereby a if any are needed to give the foamable composition as set desirably high crush strength is imparted to the product forth hereinbefore, readily can be made to the molten slag foam. Metal oxide concentrations as low as about 3 45 as produced. Alternatively, the ingredients can be mixed to 4 percent have produced foams showing very satiswith the solidified cold product, preferably finely divided, factory crush strengths. Concentrations of metal oxide to give the operable composition and this subsequently as high as 30 percent or more can be used. fused.

The metal oxides can be used alone or as mixtur s In preparing the foams, generally the solidified metal in the mix. A convenient source of these materials are silicate-sodium oxide glass mixture resulting either from the residues (sLags) of native ores such as the hematite the ore processing or by direct fusion, is mixed with iron ores and tacohite iron ores from which substantially Water and heated, with or without agitation, while perall of the iron values have been removed. To illustrate, mitting water to vaporize from the system. The heatthe nominal concentrations of impurities present in iron ing is continued until a viscous solution, having the conores which normally end up in slag as set forth in Iron SiSlenCY Of a molten tar, results and a skin o film Ore, published by American Iron Ore Association, Cleveforms on the exposed surface of the reaction mass.- The land, Ohio (1958) and Iron Ores Analyses and Data viscous material then is poured into a mold in which 1959, published by the M. A. Hanna Company, Agent, foaming to take p The mold q PP with Cleveland, are as follows. (The percentages shown regas Veht- The mass in the mold is p y heated 10 a f to h metal id temperature at least that at which steam is formed in Percent the system whereby water is removed from the mass Manganese 05,014 s steam. As the water vapor leaves the mass, the Aluminum 03 to 8 melting point of the mass is increased and its water Calcium (aslime) 003,0 4 solubility decreased. As the heatlng proceeds, small Magnesium 0,06 4 Water p r gas b bles are trapped within and through- These ore residues provide the additional advantage of furnishing a large amount of the silica required in the composition as silicon dioxide comprises from about 2 to 20 percent of these native materials and up to 45 percent or more of some of the siliceous type ores.

out the formed mass thereby providing a light weight multi-cellular foam. The cells communicate one with another within a given molded form. The foamed 0 product as produced has a substantially smooth porebeneath which is entrapped the cellular insulating network of voids or connected cells.

The silicate-sodium oxide foamable composition preferably is particulated prior to mixing with the water. Ordinarily particles of from about 0.05 to about 0.25 inch are employed although larger or smaller particles can satisfactorily be used. Small particles provide a greater surface area and therefore an increased rate of solution in the water.

In the aqueous reaction mixture, 100 parts by weight of the solid silicate-sodium oxide fused product will be used with from about 40 to about 400 parts or more by weight water. Ordinarily about equal weights of the solid and water are used.

The time of heating to effect solution of the silicatesodium oxide glass will vary depending upon the type of evaporator employed, the total heat energy utilized and the amount of reactants as is apparent to one skilled in the art. As an illustration, about 1500 grams each of powdered foamable solid and water in an open stainless steel beaker were heated at boiling temperatures over an electric hot plate. The mix was stirred continuously by means of a mechanical stirrer during the heating. After about one hour, a thick viscous, but still pourable, mass remained. Analysis indicated about 25% of the water had been evaporated. This material when poured in a mold and heated gave a very satisfactory foam.

The actual foaming temperatures to be employed are from about 300 to about 700 C. and preferably from about 400 to about 500 C. The foaming readily can be carried out by placing the mold and contents directly in an oven or heating by other means apparent to one skilled in the art.

The time required for completion of foaming is dependent primarily on the size of the foamed article and the foaming temperature employed. Ordinarily foaming times of from about several minutes to several hours or more are used. A test specimen 2 inches thick and 4 inches square prepared from the illustrative solution described directly hereinbefore was completely foamed at a temperature of 450 C. in 60 minutes. Continuing the heating for additional periods did not alter or adversely affect the foamed product.

To facilitate removal of the foamed product from the mold after foaming, a layer of asbestos paper, kraft paper or other similar material which is not wetted by the viscous solution can be employed as a mold lining. Kraft paper was found to be most satisfactory as this was not wetted by the liquid foamable composition and after the foaming operation was either charred or flake carbonized. This could be easily brushed or removed from the surface of the molded foam by light abrasive action, as by sanding.

If no lining was employed in the foaming process it was found that the foamed product tenaciously adhered to the mold wall. This product and process therefore unexpectedly provides a means for producing insulating construction panels for building purposes, refrigeration assemblies, etc. in a single operation. The outer walls of the laminate can be of metal, wood, glass and the like materials which can be subjected to the foaming temperatures. These can be assembled so as to actually be the mold container or alternatively can be employed as lining in other molds. The foamable liquid composition of the present invention can be placed therein and foamed whereby an extremely strong bond is formed joining these in a unitized structure.

Alternatively, the foam can be produced in a predetermined shape using the hereinbefore described molding procedure. The material can be removed from the mold and joined to covering materials by adhesives to provide laminated structures. This latter procedure is employed for preparing fabrications when the covering material is not stable to the foaming temperature or may be attacked in a detrimental manner by the alkaline liquid foamable composition.

The resulting foamed product can be crushed, ground or otherwise particulated and used in this form as a light weight aggregate filler, for pour insulation, etc.

The foamed product can be coated with a glazing compound or other coloring agent used with ceramics and the so-coated foamed product then can be fired. In this operation, the ceramic coating becomes a part of the surface of the foam and imparts a permanent color to the product.

Cuttings, rejects, grinding wastes and the like resulting from the production of the foamed product are not lost but readily can be reprocessed through the solution forming stage and refoamed. Since no adulterant or chemical foaming agent is used in the process, the foamable compositions can be reconstituted merely by adding water to a product that has been taken through the foaming step.

The following examples will serve to illustrate further the present invention but are not meant to limit it thereto.

Example 1 A weighed portion of hematite iron ore having the following composition:

Percent 86.5 0.1

0.0 0.02 Volatile (lost on ignition) Balance was blended with a finely divided coal (fixed carbon content 92.4%) and flake caustic (NaOH) to give a total mix of about 5 pounds haVingTa G Ee O ratio of 3 and a SiO /Na O ratio of l. The mix was heated in a No. 10 plumbago crucible over a gas flame to a temperature of about 1450 C. at atmospheric pressure. The mix was maintained at the indicated temperature for about 50 minutes. Following this reaction period the molten mass was poured into a graphite crucible whereupon two layers formed. The more dense phase was substantially all metallic iron and the lighter phase was a green, glass-like, alkali silicate based slag. Following cooling and sodification, the two phases readily were separated.

This glass phase analyzed as follows:

Percent F6203 0.2 SiO 40.1 MnO 2.5 A1 0 21.5 CaO 0.8 MgO 0.7 S 0.2 TiO 0.9 Na O 32.6

The presence of CaO and MgO in the glass results from the presence of these values in the coal used as reductant. 1 The Na O/SiO molar proportion in this glass is about The glass was reduced to approximately pea size particles in a jaw crusher mill and the small amount of metallic iron globules carried into the glass during the reduction stage substantially completely was removed by magnetic action. The glass was further comminuted on a micro-pulverizer. Following this operation, the last of the metallic iron was removed therefrom by magnet.

About grams of the powdered glass was placed into a 500 milliliter stainless steel beaker and about 100 grams of distilled water was added with stirring. The resulting mixture was heated to boiling with continuous stirring and this action continued until about 20 percent of the water had evaporated. This took about one hour.

6 Example 3 The glass composition as used in Example 2 was used to prepare a metal-foamed glass sandwich panel. For this operation stainless steel linings of about 1 inch g gi a thick viscous liquid having 5 thick and about 6 /2 inches square were placed in the a l s m n1 su mold. The viscous foamable 11 1nd was then laced The viscous liquid was P i an iron mold m into the mold and foamed as de cribed in Exam ple l. at; fi of zitregular g f fi removal}: %is the resulting laminate was removed from the mold, an?...:aa.r aaidartisan ;1.2:. .0 It to t e meta sur ace ormin a san wic ane 'wit a Kraft Paper- A volume of the foamable comPosition foam glass core about 1 inih thick and gutside skins equal to about 0.6 the volume of the mold cavity was of Stainless Steel The glassqtbmbtal bond of these 73- Aferhthe mold had been h top g panels -was exceedingly strong and the outer metal covergait; nedngriim at; 51123111313113 ciczgzms p Aacszeg1 emmz; sgrgeecgzg 15 bugs could rtihot be rippeiif from the core without actually estroying e core ltse a sists:s atte s;Pinstripe:1i: In to describe a 1 examp es, a composition containing a an i 2 in marinas;assassinate? mlf g gg of 1w a The product had carbonized paper clinging to its outg g g gi s 2: g r g gflgb g 33 er surfaces which was easily removed by light abrading glass can be crushed and a mixture containing about action. The outer wall surfaces of the foamed product 100 parts of the Solid and about 50 parts water can be smoofh and Pore freesectionirfg the Product prepared. This mixture can be heated to produce a thick dicated an internal structure of substantially homogeneous viscous solution which Subsequently can be foamed at connected cells" a temperature of about 300 C.

Example 2 Additionally, -a mixture of sodium oxide and silicon Using the same procedure as described for Example Oxide having Nazo/sioz PTOPOTtiOBS and containing 1, a similar light weight foam was produced from a about 3 Pefcfint EQ can be f q 11110 a glass- Thls glass obtained in the caustic-carbon reduction of ataconite glass can be finished 1M0 finely dlvlded f and about iron ore. The glass produced analyzed to have the fol- 100 P 0f th1$ 8 can be admlXed Wlth about 400 lowing composition: parts Water. ThlS mixture can be heated until a thick Per em viscous liquid results. This material can be foamed by Fe O 7 heating at about 700 C. The resulting foam after re- 6 3 moval from the mold can have a plywood cover placed on one of the wall surfaces and a plaster type wall board material placed on the other. These readily can be C fastened to the foam by means of common adhesive 0 materials used in the construction art as is understood by S g 40 one skilled in this art. The resulting sandwich panel provides a lightweight unit having excellent thermal rea sistances and a fire proof core.

2 Various modifications can be made in the present in- The N21 O/SiO molar proportions of this glass are vention without departing from the spirit or scope there- 1/ 1.75. of for it is understood that we limit ourselves only as A number of runs were made in which foams were predefined in the appended claims. pared either directly from this glass product or where We claim: excess metal oxide values were incorporated into the mix 1. A foamable silicate composition which comprises; prior to or during the liquification stage in the foaming sodium oxide and silicon dioxide having a Na O/SiO process. The foamable liquid and foams themselves were molar proportion of about 1/ 1.3 and contains on the total produced following the same procedure described in Excomposition weight about 21.5 'weight percent A1 0 ample-,1, about 2.5 weight percent MnO about 0.8 weight pera e w 1c 0 ows summarizest eresu tso tese cen a a u welg t percent g a ut Tbllh'hfll h lfh tCO bot07 h M0 be 09 mm weight percent TiO and about 0.2 weight percent Fe O TABLE I Reactants Additive Solution Foaming Formation Conditions DFoarrti R k BS Run N0 Glass Hi0 Type Grams (ii Ci em 5 (g,) T., c Min. 'I., 0. Min.

500 500 104 50 450 Grey colored foam, uniform cell structure, no breaks or cracks. 12?) (C358 8g Googgtrong foam.

8 200 200 (39.01; 1.0 35 450 Liquid was more viscous than glass alone. Good, strong foam. 500 250 A110; 25 90 960 00 Good strong, low density foam. 1,000 500 A110; 100 9 4 0 60 Gifted strong very low density 0am. 200 200 Alflggmm. 1( (2) f? :23 2g 0 3 Good strong foam. 8 33 2 i so 450 60 3: 200 200 10 50 450 60 Do. 0 200 20 40 450 60 Good strong foam. Appeared to be rather dense. 200 290 6 (2 45 450 60 Good strong foam of rather high density.

1 Extended time used to determine efiect of long treatment on foam production. 2 Boiling.

2. A foamable silicate composition which comprises; sodium oxide and silicon dioxide having a Na O/SiO molar proportion of about 1/ 1.75 and contains on the total composition weight about 7.7 weight percent F6203, about 1.7 weight percent MnO about 1.3 weight percent Al O about 0.8 weight percent CaO, about 0.6 weight percent MgO and about 0.6 weight percent TiO References Cited by the Examiner UNITED STATES PATENTS 2,237,037 11/1937 Lyt le 65-22 2,620,597 12/1952 Ford 65-22 2,764,493 9/1956 Vogelbeck 106-51 X 2,830,000 4/1958 Labino 161--196 2,837,873 6/1958 Lynsavage 6522 2,955,947 10/1960 Gmeiner et a1. 106-40 OTHER REFERENCES Segnit: Further Data on the System Na OCz O-SiO 251 Amer. J. of Sci., 586-601, published August 1953.

DONALL H. SYLVESTER, Primary Examiner.

15 EARL M. BERGERT, Examiner.

W. I. VAN BALEN, G. R. MYERS, Assistant Examiners. 

1. A FOAMABLE SILICATE COMPOSITION WHICH COMPRISES: SODIUM OXIDE AND SILICON DIOXIDE HAVING A NA2O/SIO2 MOLAR PROPORTION OF ABOUT 1/1.3 AND CONTAINS ON THE TOTAL COMPOSITION WEIGHT ABOUT 21.5 WEIGHT PERCENT AL2O3, ABOUT 2.5 WEIGHT PERCENT MNO2, ABOUT0.8 WEIGHT PERCENT CAO, ABOUT 0.7 WEIGHT PERCENT MGO, ABOUT 0.9 WEIGHT PERCENT TIO2, AND ABOUT 0.2 WEIGHT PERCENT FE2O3. 